Deployable aerodynamic side panel system

ABSTRACT

An active side panel assembly having at least one deployable panel ( 22 ) and at least one actuator ( 30 ). The deployable panel deploys and retracts based on vehicle requirements and provides valueable reduction in vehicle drag, thereby reducing emissions and improving fuel economy. Additionally, it allows for the system to retract so the vehicle can still meet ground clearances, ramp angles, off-road requirements, etc. The active side panel provides a fully deployable system with object detection, declutching of the actuator to help prevent damage, and communication with the vehicle to determine proper deployment and function.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of U.S. patent application Ser. No.15/128,023, filed Sep. 21, 2016, which is a National Stage ofInternational Application No. PCT/US2015/021701, filed Mar. 20, 2015,which claims benefit of U.S. Provisional Patent Application No.61/968,482 filed Mar. 21, 2014. The disclosures of the aboveapplications are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to an active side panel assemblyintegrated into a side panel for automotive applications.

BACKGROUND OF THE INVENTION

There has been increasing desire to manufacture vehicles that meet orexceed environmental improvement requirements. However, there is aconsiderable loss of aerodynamic efficiency in vehicles, in particular,vehicles with higher ground clearances such as pickup trucks, sportutility vehicles, and other vehicles, due to the airflow into theunderside of the vehicle.

Therefore, having parts with improved aerodynamics has become awell-received option typically effective toward helping to advancestandards such as milleage requirements. There are also several otherfactors that must be considered including aerodynamic load, part weight,cost, ground clearance, complexity and durability.

Typical systems, such as fixed panels, or motorized deployable panels,do not meet requirements. Known systems do not have a proper sealed andclutchable actuator with communication capability and life cycledurability, capabillity for object detection, and are not durable andaerodynamically effective. Typical systems also do not have the abilityto detect objects in the event there is an object or ground surface inthe way during deployment or object/ground contact while deployed.

Accordingly, there remains a need in the art to provide an automaticallydeployable structure under predetermined conditions that providesimproved arodynamics.

SUMMARY OF THE INVENTION

The present invention is directed to an active side panel assemblyhaving at least one deployable panel that moves between at least astowed position and a deployed position driven by at least one actuator,such as a sealed, clutchable actuator that has communication capabilitywith the vehicle. The deployable panel improves arodynamics and is partof a rocker panel system/module and/or side vehicle panel/framing. Theassembly does not require manual deployment and is only utilized whennecessary; at predetermined vehicle speeds under predeterminedconditions with no ground surface or object interference.

When the deployable panel is in an extended or deployed position, thedeployable panel improves airflow under predetermined conditions, e.g.,vehicle speeds in the range of at least 30 miles per hour. When thedeployable panel is in a retracted or stowed position, the deployablepanel generally folds or otherwise moves out of the way under thevehicle to improve vehicle ground clearance and prevent damage due toground/terrain/objects in the way during deployment or coming incontact. The active side panel assembly provides a fully deployablesystem with object detection, declutching to help prevent damage, e.g.,to protect the deployable panel under higher predetermined loads, isunder the vehicle when stowed for ground clearance and usability, hascommunication with the vehicle to determine proper deployment andfunction, and is suitable to meet automotive specifications andfunctionality.

Utilization of the side panel system that deploys and retracts based onvehicle requirements provides valueable reduction in vehicle drag,thereby reducing emissions and improving fuel economy. Additionally, itallows for the system to retract up adjacent the rockersystem/module/frame so the vehicle can still meet ground clearancerequirements and reduce or eliminate potential for damage due to contactwith objects or the driven ground surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of a vehicle with a deployable side panelassembly in a stowed position.

FIG. 2 is a perspective view of the vehicle with the deployable sidepanel assembly shown in a deployed position, in accordance with thepresent invention;

FIG. 3A is a broken-away side view schematic of a deployable side panelassembly in an environment of use illustrating a deployable panelrotating between a stowed position and a deployed position, inaccordance with the present invention;

FIG. 3B is a broken-away perspective view of the deployable panel ofFIG. 3A in the stowed position;

FIG. 3C is a broken-away perspective view of the deployable panel ofFIGS. 3A-3B in the deployed position;

FIG. 4A is a broken-away side view schematic of a deployable side panelassembly illustrating a deployable panel rotating between a stowedposition and a deployed position, in accordance with a second embodimentof the present invention;

FIG. 4B is a broken-away perspective view of the deployable panel ofFIG. 4A in the stowed position;

FIG. 4C is a broken-away perspective view of the deployable panel ofFIGS. 4A-4B in the deployed position;

FIG. 5A is a broken-away side view schematic of a deployable side panelassembly illustrating a deployable panel rotating between a stowedposition and a deployed position, in accordance with a third embodimentof the present invention;

FIG. 5B is a broken-away perspective view of the deployable panel ofFIG. 5A in the stowed position;

FIG. 5C is a broken-away perspective view of the deployable panel ofFIGS. 5A-5B in the deployed position;

FIG. 6A is a broken-away side view schematic of a deployable side panelassembly including an integrated slide out deployable panel shownbetween a stowed position and a deployed position, in accordance with afourth embodiment of the present invention;

FIG. 6B is a broken-away perspective view of the deployable panel ofFIG. 6A in the stowed position;

FIG. 6C is a broken-away perspective view of the deployable panel ofFIGS. 6A-6B in the deployed position;

FIG. 7A is a broken-away side view schematic of a deployable side panelassembly including a slidable deployable panel shown between a stowedposition and a deployed position, in accordance with a fifth embodimentof the present invention;

FIG. 7B is a broken-away perspective view of the deployable panel ofFIG. 7A in the stowed position;

FIG. 7C is a broken-away perspective view of the deployable panel ofFIGS. 7A-7B in the deployed position;

FIG. 8A is a broken-away side view schematic of a deployable side panelassembly including a hinged deployable panel shown between a stowedposition and a deployed position, in accordance with a sixth embodimentof the present invention;

FIG. 8B is a broken-away perspective view of the deployable panel ofFIG. 8A in the stowed position;

FIG. 8C is a broken-away perspective view of the deployable panel ofFIGS. 8A-8B in the deployed position;

FIG. 9A is a broken-away side view schematic of a deployable side panelassembly including a hinged deployable panel shown between a stowedposition and a deployed position, in accordance with a seventhembodiment of the present invention;

FIG. 9B is a broken-away perspective view of the deployable panel ofFIG. 9A in the stowed position;

FIG. 9C is a broken-away perspective view of the deployable panel ofFIGS. 9A-9B in the deployed position;

FIG. 10A is a broken-away side view schematic of a deployable side panelassembly including a hinged deployable panel shown between a stowedposition and a deployed position, in accordance with a eighth embodimentof the present invention;

FIG. 10B is a broken-away perspective view of the deployable panel ofFIG. 10A in the stowed position;

FIG. 10C is a broken-away perspective view of the deployable panel ofFIGS. 10A-10B in the deployed position;

FIG. 11A is a broken-away side view schematic of a deployable side panelassembly including a deployable panel with a flexible hinge shownbetween a stowed position and a deployed position, in accordance with aninth embodiment of the present invention;

FIG. 11B is a broken-away perspective view of the deployable panel ofFIG. 11A in the stowed position;

FIG. 11C is a broken-away perspective view of the deployable panel ofFIGS. 11A-11B in the deployed position;

FIG. 12A is a broken-away side view schematic of a deployable side panelassembly including a scissor hinge panel shown between a stowed positionand a deployed position, in accordance with a tenth embodiment of thepresent invention;

FIG. 12B is a broken-away perspective view of the deployable scissorhinge panel of FIG. 12A in the stowed position;

FIG. 12C is a broken-away perspective view of the deployable scissorhinge panel of FIGS. 12A-12B in the deployed position;

FIG. 13A is a broken-away side view schematic of a deployable side panelassembly including a deployable panel of stretchable material shownbetween a stowed position and a deployed position, in accordance with aneleventh embodiment of the present invention;

FIG. 13B is a broken-away perspective view of the deployable panel ofFIG. 13A in the stowed position;

FIG. 13C is a broken-away perspective view of the deployable panel ofFIGS. 13A-13B in the deployed position;

FIG. 14A is a broken-away side view schematic of a deployable side panelassembly including a deployable panel of soft material shown between astowed position and a deployed position, in accordance with an twelfthembodiment of the present invention;

FIG. 14B is a broken-away perspective view of the deployable panel ofFIG. 14A in the stowed position;

FIG. 14C is a broken-away perspective view of the deployable panel ofFIGS. 14A-14B in the deployed position;

FIG. 15A is a broken-away side view schematic of a deployable side panelassembly including a rollable panel shown between a stowed position anda deployed position, in accordance with a thirteenth embodiment of thepresent invention;

FIG. 15B is a broken-away perspective view of the deployable panel ofFIG. 15A in the stowed position;

FIG. 15C is a broken-away perspective view of the deployable panel ofFIGS. 15A-15B in the deployed position;

FIG. 16A is a broken-away side view schematic of a deployable side panelassembly including a housing and a deployable panel, the panel shownbetween a stowed position and a deployed position, in accordance with afourteenth embodiment of the present invention;

FIG. 16B is a broken-away perspective view of the deployable panel ofFIG. 16A in the stowed position;

FIG. 16C is a broken-away perspective view of the deployable panel ofFIGS. 16A-16B in the deployed position;

FIG. 17A is a broken-away side view schematic of a deployable side panelassembly including pivotal linkages connected to a deployable panel, thepanel shown between a stowed position and a deployed position, inaccordance with a fifteenth embodiment of the present invention;

FIG. 17B is a broken-away perspective view of the deployable panel ofFIG. 17A in the stowed position;

FIG. 17C is a broken-away perspective view of the deployable panel ofFIGS. 17A-17B in the deployed position;

FIG. 18A is a broken-away side view schematic of a deployable side panelassembly including rotatable bracket members connected to a deployablepanel, the panel shown between a stowed position and a deployedposition, in accordance with a sixteenth embodiment of the presentinvention;

FIG. 18B is a broken-away perspective view of the deployable panel ofFIG. 18A in the stowed position;

FIG. 18C is a broken-away perspective view of the deployable panel ofFIGS. 18A-18B in the deployed position;

FIG. 19A is a broken-away side view schematic of a deployable side panelassembly including a deployable panel including an integrated slide outpanel, the panel shown between a stowed position and a deployedposition, in accordance with a seventeenth embodiment of the presentinvention;

FIG. 19B is a broken-away perspective view of the deployable panel ofFIG. 19A in the stowed position;

FIG. 19C is a broken-away perspective view of the deployable panel ofFIGS. 19A-19B in the deployed position;

FIG. 20A is a broken-away side view schematic of a deployable side panelassembly including a screw threaded member and a deployable panel, thepanel shown between a stowed position and a deployed position, inaccordance with an eighteenth embodiment of the present invention;

FIG. 20B is a broken-away perspective view of the deployable panel ofFIG. 20A in the stowed position;

FIG. 20C is a broken-away perspective view of the deployable panel ofFIGS. 20A-20B in the deployed position;

FIG. 21A is a broken-away side view schematic of a deployable side panelassembly with a deployable panel shown in a deployed position, inaccordance with a nineteenth embodiment of the present invention;

FIG. 21B is a broken-away perspective view of the deployable panel ofFIG. 21A in the stowed position;

FIG. 21C is a broken-away perspective view of the deployable panel ofFIGS. 21A-21B in the deployed position;

FIG. 22A is a broken-away side view schematic of a deployable side panelassembly a deployable hinged sail panel shown in a deployed position, inaccordance with a twentieth embodiment of the present invention;

FIG. 22B is a broken-away perspective view of the hinged sail panel ofFIG. 22A in the stowed position;

FIG. 22C is a broken-away perspective view of the hinged sail panel ofFIGS. 22A-22B in the deployed position;

FIG. 23A is a broken-away side view schematic of a deployable side panelassembly with a deployable panel shown in a deployed position, inaccordance with a twenty first embodiment of the present invention;

FIG. 23B is a broken-away perspective view of the deployable panel ofFIG. 23A in the stowed position;

FIG. 23C is a broken-away perspective view of the deployable panel ofFIGS. 23A-23B in the deployed position;

FIG. 24 is an exploded view of an exemplary actuator with internalclutching for deploying/stowing the active side panel assembly, inaccordance with the present invention; and

FIG. 25 is a perspective view of the actuator of FIG. 24 without thehousing for clarity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring to FIGS. 1-3C generally, in accordance with the presentinvention, there is provided an active side panel assembly generallyshown at 10 for a vehicle 12. The active side panel assembly 10 ismovable between a stowed position and a deployed position, and theassembly 10 is operably supported and connected to a rocker panelassembly 14 portion of the vehicle 12 such that the assembly 10 is ableto deploy and retract automatically under predetermined conditions.

Generally, the rocker panel assembly 14 includes at least one outerrocker panel 16 and inner rocker panel 18 with an inner reinforcementpanel 20 therebetween. The rocker panel 14 is located along the lowerside of the vehicle 12 between wheel wells and/or between the frontwheel well and front of cargo bed. The assembly 10 is operably connectedto vehicle framing and/or the rocker panel assembly 14 of the vehicle 12using a nut and bolt combination, however, it is within the scope of theinvention that other fasteners, such as rivets, or in combination with aplurality of attachment brackets may be used as well.

The active side panel assembly 10 includes at least one deployable panel22 rotatably connected to the vehicle 12. Typically, the panel 22 ismoveable between at least a deployed position and a stowed position.However, depending on the application the deployable panel 22 isslidable, extendable, articulatable, stackable, pivotable, rollable,elevatable, inflatable, foldable, collapsible, stretchable,translatable, combinations thereof or otherwise connected and deployablein the side panel 20 area depending on the application.

A pair of hinges 24 are connected toward a lower edge 26 of the rockerpanel assembly 14, e.g., inner rocker panel 18, to the first end 28 ofthe deployable panel 22. The panel 22 is adapted for attachment to thepair of hinges 24 which can be any hinge arrangement suitable forpredetermined cycling and durability requirements. Typically, the loweredge 26 region has a ‘U’ shaped cross-section, cutout or notch and eachhinge is fastened in the region, e.g., directly or by way of a fasteneror pin going through diverging side walls of the cutout. However,depending on the application hinges are bolted, screwed, welded,riveted, secured with adhesive and/or epoxy, combinations thereof orotherwise connected to the panel 22 and rocker panel assembly 14 and/orother framing or chassis member(s) depending on the application.Alternatively, molded-in panel features which are used to attach toopposing vehicle features and/or in combination with at least onefastener for each hinge or the like may be used to pivotally secure thepanel 22 to the vehicle 12 and allow deployment of the panel 22.

The first end 28 of the deployable panel 22 has a predetermined lengthand is angled suitably for providing clearance with the rocker panelassembly 14 and cycling the integrally formed distal end portion 36 ofthe deployable panel 22 from the deployed, e.g., generally vertical, tostowed, e.g., generally horizontal, positions.

At least one actuator 30 is connected to a respective drive shaft 32operably coupled to the deployable panel 22. Generally, the actuator 30is sealed within the rocker panel assembly 14 or other vehicle structureto afford further protection from impact and/or the environment.Typically, the actuator 30 is embedded within the rocker panel assembly14 or other vehicle structure to rotate the panel 22 up/down.Preferably, the actuator 30 and drive shaft 32 are enclosed within therocker panel assembly 14 between the outer panel 16 and inner panel 18,generally centrally located toward the lower end of the rocker panelassembly 14 (See FIG. 2 indicated in phantom). Preferably, one actuator30 and a single driving rotating shaft is used and rotates the panel 22up/down. Optionally, access panels may be provided for servicing andmaintenance of the actuating arrangement.

The actuator 30 rotates the drive shaft 32 to drive the panel 22downward and forward during deployment of the panel 22 to the deployedposition (see FIGS. 2, 3C). When the active side panel assembly 10 is inthe extended/down or deployed position, the deployable panel 22 improvesairflow.

The actuator 30 also rotates the drive shaft 32 in the oppositedirection to move the panel 22 upward and rearward out of the way to thestowed position (see FIGS. 1, 3B, 3A), e.g., generally horizontal. Whenthe active side panel assembly 10 is in the retracted/up or stowedposition, the deployable panel 22 is folded up under the vehicle.

When the active side panel assembly 10 is the stowed position, thedeployable panel 22 generally moves or folds out of the way under thevehicle to increase ground clearance. Optionally, the first extendingpanels can retract and extend in and out of a hollow portion of therespective frame, more preferably, retract and extend from an open areaor gap between underbody components under the vehicle. Optionally, anadditional panel or other existing structural member can be providedunder the vehicle 12 with a depression or the like having apredetermined depth formed therein and sized to receive at least part ofthe panel 22 within the depression when in the stowed position tofurther help prevent contact with the stowed panel 22 by objects andground surface.

The actuator 30 is a rotary actuator, e.g., with feedback options,hex-type, screw-type drive, higher speed actuator, electric, mechanical,linear, e.g., with current override circuits, declutching, hydraulic,pneumatic, extending, power lift actuator, or any other actuators andcombinations thereof depending on the application and predeterminedvehicle needs.

In a preferred embodiment, the actuator 30 has internal clutching thatreacts to certain conditions by de-clutching or disengaging gearsallowing the deployable panel 22 to stop deployment to help preventdamage to the active deployable panel 22. Upon impact to the deployablepanel 22, e.g., by a ground surface or object on the ground, theactuator 30 will clutch to disengage the gearing so that the deployablepanel 22 can move freely out of the way. The actuator 30 itself does notmove out of the way upon impact to the deployable panel 22. In the eventthere is ground/terrain/objects in the way during deployment of thepanel 22, the actuator 30 can clutch to disengage the gearing or theactuator 30 can retract the deployable panel 22 back to the stowedposition. Typically, the actuator 30 senses current spikes and causesthe actuator 30 to react to certain conditions, e.g., sensing of objectshitting the deployable panel 22 induces the actuator 30 to disengage thegearing.

The actuator 30 is generally sealed and has communication capabilitywith the vehicle 12. The actuator 30 and the vehicle 12 also communicateto deploy and retract the deployable panel 22 based upon predeterminedconditions such as vehicle speed, wind direction, e.g., average winddirection is unfavorably about 5° yaw, etc. By way of example, thedeployable panel 22 is stowed under vehicle 12 and when the vehicle 12reaches a predetermined speed, e.g., about 30-40 mph, the deployablepanel 22 folds downward to the deployed position and stays down untilthe vehicle drops back down to below the predetermined speed or otherpredetermined conditions for continued deployment are no longer met.

When the deployable panel 22 is up in the stowed position it is extendedpartially under the vehicle 12. Generally, extending 4 to 12 inches,typically, 5 to 10 inches, preferably, 5 to 8 inches.

When the deployable panel 22 is down in the deployed position it isextended generally about one quarter to one half of the distance to thetraversed ground surface, preferably, about one third of the distance.

When the deployable panel 22 is down in the deployed position it isgenerally extending vertically, and prevents air from swirling under thevehicle and reduces drag. Typically, the panel 22 is extended to about90°, traverse to the underside of the vehicle, such that the panel 22 isalong the same vertical plane as the vehicle 12 side panel to helpprevent air from ducking under the vehicle 12 where it is turbulent dueto all of the components under the vehicle 12. Alternatively, the panel22 is angled inward, e.g., generally, zero to 60 degrees under vertical,typically, five to thirty degrees, preferably, fifteen to thirtydegrees, most preferably, five to fifteen degrees maximum. In accordancewith a most preferred embodiment, the panel 22 is not at an angle whenin the deployed position.

Both ends 34 of the formed panel 22 are generally straight. Depending onthe particular application, the ends 34 have different profiles withoutdeparting from the scope of the invention.

The active side panel assembly 10 is depicted located on the driver sideof the vehicle 12 generally extending along the bottom edge of thevehicle from behind the front wheel well to the front of the rear wheelwell. Another active side panel assembly 10 is symmetrical located onthe passenger side of the vehicle 12. Both active side panel assemblies10 are synchronized such that they extend and retract in unison underpredetermined conditions.

Referring generally to FIGS. 24-25, the actuator 30 used in anyembodiment can be declutchable. An exemplary actuator assembly withinternal clutching is shown generally at 310, comprising a clutchsystem, generally shown at 312, as will be explained in further detailbelow. Generally, there is provided a sealed actuator with internalclutching assembly in accordance with the present invention whichprovides desirable higher cycle durability and capability combined witha water tight arrangement for use, by way of example, in underbodyenvironments exposed to the elements. The sealed actuator with internalclutching assembly further provides a safety override clutch systemwhich allows the actuator to rotate under predetermined conditions,e.g., predetermined high loads, to help protect a motor and othercomponents of the actuator with internal clutching assembly, as will beexplained in greater detail below. When subjected to abnormal loads or apredetermined amount of force or other predetermined conditions, theactuator with internal clutching assembly will move features out of theway to help prevent damage thereto.

Referring to FIGS. 4A-4C generally, in accordance with a secondembodiment of the present invention, an active side panel assemblygenerally shown at 110 for a vehicle is identical to the firstembodiment except that the deployable panel 122 is rotatably connectedto an intermediary fixed panel 138 operably connected to the rockerpanel assembly 114. Just as with the first embodiment, the deployablepanel 122 is rotated down/up by the at least one actuator between adeployed position and stowed position. However, the deployable panel 122is hinged under the intermediary fixed panel 138 such that when stowed,the deployable panel 122 is under and behind the fixed panel 138. Inparticular, the deployable panel is under a distal end portion 136 ofthe fixed panel 138 and behind a lower depending flange 140 of the fixedpanel such that when stowed the deployable panel 122 is not seen fromthe side of the vehicle. The intermediary fixed panel 138 also has anupward depending portion 140, both the lower and upper dependingportions 138,140 extending at a predetermined angle. When driven to thedeployed position, the deployable panel 122 rotates downward and theupper end of the panel 122 remains behind the angled lower dependingportion 138 of the fixed panel.

When in the deployed position the panel 122 is angled inward, e.g.,generally, 15 to 60 degrees under vertical, typically, five to thirtydegrees, preferably, fifteen to thirty degrees, most preferably, five tofifteen degrees maximum.

Referring to FIGS. 5A-5C generally, in accordance with a thirdembodiment of the present invention, an active side panel assemblygenerally shown at 210 for a vehicle is identical to the firstembodiment except that the deployable panel 222 is rotatably connectedto the inner rocker panel 218 by at least a pair of hinges 224. Thefirst end 228 of the deployable panel 222 has a predetermined length andis angled in the opposite direction as the first embodiment.

Referring to FIGS. 6A-6B generally, in accordance with a fourthembodiment of the present invention, an active side panel assembly 410generally shown at 410 for a vehicle is identical to the firstembodiment except that the deployable panel 422 is generally ‘U’ shapedand incorporates a slide out panel 442 slidably connected to thedeployable panel 422 to slide in/out. The deployable panel 422 isoperably rotatably coupled to the rocker panel assembly 414 and rotatedup/down by the at least one actuator between a deployed position andstowed position. However, the slide out panel 442 is slidable receivedwithin the deployable panel 422 such that when stowed, the slide outpanel 442 is slid into the deployable panel 422 and not seen when thedeployable panel 422 is in the stowed position. When the active sidepanel assembly 410 is in the extended/down or deployed position, thedeployable panel 422 and slide out panel 440 improve airflow. To deploythe assembly the panels 422, 442 are rotated downward generally 90° as aunit and the slide out panel 442 is then slid downward to the fullyextended position by the same or an additional actuator. To stow theassembly, the slide out panel 442 slides into the deployable panel 422and the panels 422, 442 are rotated upward as a unit into the areagenerally behind the rocker panel assembly 414.

Referring to FIGS. 7A-7C generally, in accordance with a fifthembodiment of the present invention, an active side panel assemblygenerally shown at 510 for a vehicle is identical to the firstembodiment except that the deployable panel 522 has a generally channelshaped proximal end 528 and has a slidably connected slide out panel 542that slides up/down. The deployable panel 522 is rotated down/up by theat least one actuator between a deployed position and stowed position.However, the slide out panel 542 is slidable received behind thedeployable panel 522 such that when stowed, the slide out panel 542 isslid behind the deployable panel 522 and is not seen when the deployablepanel 522 is rotated up to the stowed position. When the active sidepanel assembly 510 is in the extended/down or deployed position, thedeployable panel 522 and slide out panel 542 improve airflow. To deploythe assembly the panels 522, 542 are rotated downward generally 90° as aunit and the slide out panel 542 is then slid downward to the fullyextended position by the same or an additional actuator. To stow theassembly, the slide out panel 542 slides behind the deployable panel 522and the panels 522, 542 are rotated upward as a unit into the areagenerally adjacent the lower end of the rocker panel assembly 514.

Referring to FIGS. 8A-8C generally, in accordance with a sixthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 610 for a vehicle. At least two panelsform an integrated folding panel indicated generally at 622 comprised ofa first panel 644 connected to a second panel 646 by at least one joint648. Each panel has a first end and a second end. The proximal end 650of the first panel 644 is pivotally connected to the rocker panelassembly 614 toward the bottom of the rocker 614. The second end of thefirst panel is pivotally connected to the first end of the second panel652 at joint 648. At least one actuator drives the integrated foldingpanel 622 downward to the deployed position (FIGS. 8A, 8C), using thesame or different actuator and drive shaft as the first embodiment. Whenthe actuator drives the integrated folding panel 622 to the stowedposition (FIG. 8B), the panels 644, 646 fold upward upon one another andsuch that the deployable panel 622 into the area generally the lower endof the rocker panel assembly 614. The assembly 610 could be jointed orhinged in the opposite direction without departing from the scope of theinvention.

Referring to FIGS. 9A-9C generally, in accordance with a seventhembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 710 for a vehicle. At least two panelsform an integrated articulatingly connected panel indicated generally at722 comprised of a first panel 744 connected between a second panel 746and the rocker panel assembly 714, e.g., inner rocker panel 718. Eachpanel has a first end and a second end. The second end of the firstpanel 744 is pivotally connected near the center of the second panel 746at pivot joint 748. The proximal end of the first panel 744 is angled apredetermined amount and pivotally connected to the rocker panelassembly 714 toward the bottom of the assembly 714. At least oneactuator drives the integrated folding panel 722 downward to thedeployed position (FIGS. 9A, 9C), using the same or different actuatorand drive shaft as the first embodiment. When deployed, an upwardportion of the second panel 746 is behind the first panel 744. Thesecond panel 746 includes a central curve so that the exposed lower halfof the second panel 746 is generally vertical. When the actuator drivesthe integrated folding panel 722 to the stowed position (FIG. 9B), thefirst panel 744 rotates upward and rearward to a generally horizontalposition causing the second panel 746 to be driven upward.

Referring to FIGS. 10A-10C generally, in accordance with an eighthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 810 for a vehicle. At least two panelsform an integrated folding panel indicated generally at 822 comprised ofa first panel 844 connected to a second panel 846 by at least a firstpivot joint 848. Each panel has a first end and a second end. Theproximal end 856 of the second panel 846 is pivotally connected to therocker panel assembly 814 toward the bottom of the rocker 814. One endof the first panel 844 is pivotally connected to the distal end of thesecond panel 846 at joint 854. At least one actuator drives theintegrated folding panel 822 downward to the deployed position (FIGS.10A, 10C), using the same or different actuator and drive shaft as thefirst embodiment. When the actuator drives the integrated folding panel822 to the stowed position (FIG. 10B), the first panel 844 rotatesupward about joint 854 and the second panel 846 rotates upward andrearward about joint 862.

Referring to FIGS. 11A-11C generally, in accordance with a ninthembodiment of the present invention, an active side panel assemblygenerally shown at 210 for a vehicle is identical to the firstembodiment except that the deployable panel 922 is rotatably connectedto the inner rocker panel 918 by at least one pair of flexible hinges956.

Referring to FIGS. 12A-12C generally, in accordance with a tenthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 1010 for a vehicle movable between astowed position and a deployed position (FIG. 12A, 12C). A deployablepanel 1022 forms a scissor hinge panel. The panel is formed of aflexible and/or soft material, e.g., fabric, vinyl or other material,and is framed in semi-rigid or rigid material along at least the topedge, bottom edge and diagonally. Typically, a screw drive and higherspeed actuator is employed. The bottom edge frame of the front frame bar1058 can be adapted such that when driven to the stowed position the bar1058 is driven upward to directly adjacent the top edge frame 1060.

Referring to FIGS. 13A-13C generally, in accordance with an eleventhembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 1110 for a vehicle movable between astowed position and a deployed position (FIG. 13A, 13C). A deployablepanel 1122 includes a panel 1122 connected to a frame 1164 and rotatablebrackets 1162 rotatable from a horizontal to vertical position. Thepanel 1122 is formed of stretchable material, e.g., rubber, and isdriven downward to the extended deployed position as the brackets 1162rotate and upward toward the rocker 1114 to the stowed position.

Referring to FIGS. 14A-14C generally, in accordance with a twelfthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 1210 for a vehicle movable between astowed position and a deployed position (FIG. 14A, 14C). A deployablepanel 1222 is connected to a frame 1264 and is foldable from thedeployed to stowed position. The panel 1222 is formed of a soft materialand is folded upward and rearward toward the rearward bottom of therocker 1214 to the stowed position. Preferably, a cable mechanism isused to the panel 1222 upward out of the way.

Referring to FIGS. 15A-15C generally, in accordance with a thirteenthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 1310 for a vehicle movable between thedeployed position (See FIG. 15A, 15C) and the stowed position (FIG.15B). The assembly 1310 includes a deployable panel 1322 and preferablyincludes an under vehicle track arrangement forming a garage door styleside panel system. A first set of rollers or the like are connectedtoward the edges of the panel 1322 to follow the track (slide or roll)in an upward/rearward direction (FIG. 15A) and vice versa when the panelis driven by the actuator. Typically, the tracks have a ‘U’ shapedcross-section and are bolted in the base of the ‘U’ to the vehicleframe, chassis or other features. However, depending on the applicationtracks are welded, riveted, secured with adhesive and/or epoxy orotherwise connected depending on the application. Optionally, each trackincludes a first end and a second end with respective stop features inthe second end.

Referring to FIGS. 16A-16C generally, in accordance with a fourteenthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 1410 for a vehicle movable between thedeployed position (See FIG. 16A, 16C) and the stowed position (FIG.16B). The assembly 1410 includes a deployable panel 1422 with a curvedend 1466 and an under vehicle housing indicated generally at 1468. Thehousing 1468 includes an elongated opening 1470 sized for the panel 1422to selectively extend downward through to the deployed position whilepreventing the curved end 1466 of the panel 1422 from moving laterallythrough the opening 1470.

Referring to FIGS. 17A-17C generally, in accordance with a fifteenthembodiment of the present invention, there is provided an active sidepanel assembly 1510 for a vehicle movable between a stowed position(FIG. 17B) and a deployed position (FIGS. 17A, 17C). A linkage assemblyindicated generally at 1572 connects the deployable panel 1522 to theunder vehicle frame, chassis or other features. Preferably, the linkageassembly is a four bar linkage. When the assembly 1510/panel 1522 isdriven to the deployed position, the linkage arms 1574, 1576 extend thepanel 1522 downward and outward to the deployed position generally belowthe rocker panel assembly 1514. When the assembly 1510/panel 1522 isdriven to the stowed position, the linkage arms 1574, 1576 retract thepanel 1522 rearward and upward to the stowed position generally behindthe rocker panel assembly 1514.

Referring to FIGS. 18A-18C generally, in accordance with an sixteenthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 1610 for a vehicle movable between astowed position and a deployed position (FIG. 18A, 18C). A deployablepanel 1622 is connected to rotatable brackets 1662 rotatable from ahorizontal to vertical position. The brackets 1662 are connected to orbehind the inner rocker panel 1618. Rotation of the brackets 1662 allowsthe panel 1622 to be driven the generally downward and upward to thedeployed and stowed position.

Referring to FIGS. 19A-19C generally, in accordance with an seventeenthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 1710 for a vehicle movable between astowed position (FIG. 19B) and a deployed position (FIG. 19A, 19C). Atleast two panels form an integrated slidable panel indicated generallyat 1722 comprised of a first panel 1744 slidably connected to and/oradjacent to a second panel 1746. The first panel 1744 is slidablyconnected adjacent the rear of the rocker panel assembly 1714, e.g.,using a track arrangement. The second panel 1746 is slidably connectedadjacent the rear of the first panel 1744, e.g., using a trackarrangement, and generally parallel therewith when in the stowedposition. When driven to the deployed position (FIGS. 19A, 19C) thefirst panel 1744 translates generally downward and forward and thesecond panel 1746 translates further downward and further and extendspast the bottom edge of the first panel 1744 in the deployed position.

Referring to FIGS. 20A-20C generally, in accordance with an eighteenthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 1810 for a vehicle movable between astowed position and a deployed position (FIG. 20A, 20C). A deployablepanel 1822 is connected to a housing indicated generally at 1868. Thehousing 1868 includes an elongated opening 1870 sized for the panel 1822to selectively extend downward through to the deployed position. Athreaded flex screw mechanism indicated 1878 is adapted to connect tothe panel 1822 such that when driven to the stowed position the panel1822 is driven upward through the opening 1870 and when driven to thedeployed position the panel 1822 is driven downward through the openinga predetermined amount.

Referring to FIGS. 21A-21C generally, in accordance with a nineteenthembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 1910 for a vehicle movable between astowed position and a deployed position (FIG. 21A, 21C). A deployablepanel 1922 is fixed in location toward one end and rotatable at a secondend. Toward the first end 1980 the panel 1922 is operably connected tothe rocker panel assembly 1914 and/or other framing or chassis member(s)depending on the application and does not rotate. Thus, the first end1980 is always exposed and in the deployed position, whether or not theassembly 1910 is deployed or stowed, while the second end 1982 is notexposed when in the stowed position. The other end 1982 is rotatablyconnected to the rocker panel assembly 14 and/or other framing orchassis member(s) depending on the application and is driven to movedownward to the deployed position and upward to the stowed positiongenerally behind the rocker assembly 1914. When deployed the second end1982 of the panel 1922 is typically the same extended height as thefirst end 1980 of the panel 1922 from the bottom of the rocker assembly1914. Predetermined angles and/or slants are contemplated for the panel1922 depending on the application without departing from the scope ofthe invention.

Referring to FIGS. 22A-22C generally, in accordance with a twentiethembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 2010 for a vehicle movable between astowed position and a deployed position (FIG. 22C). A deployable panelgenerally indicated at 2022 is provided with a first panel 2044connected in front of a second panel 2046. The first and second panel2044, 2046 cross and the deployable panel 2022 is connected generallytoward the centerline of the assembly 2010 by a bracket member 2062 orother fastening member to the rocker panel assembly 2014 and/or otherframing or chassis member(s) depending on the application. The panel2022 is rotatably connected and adapted such that both ends (one end ofthe first panel 2044 and one end of the second panel 2046 only) movedown/up to the deployed/stowed positions. Predetermined angles and/orslants are contemplated for the panels depending on the applicationwithout departing from the scope of the invention.

Referring to FIGS. 23A-23C generally, in accordance with a twenty firstembodiment of the present invention, there is provided an active sidepanel assembly generally shown at 2110 for a vehicle movable between astowed (FIG. 21B) position and a deployed position (FIG. 21C). Thedeployable panel 2122 is operably rotatably connected to the rockerpanel 2111 and/or other framing or chassis member(s) depending on theapplication and adapted via attachment member 2162 to allow at least oneend of the panel 2122 to rotate downward/upward. When deployed one endof the panel 2122 is lower than the other end. Any number of suitablepredetermined angles and/or slants are contemplated for the panel 2122depending on the application without departing from the scope of theinvention.

Referring generally to FIGS. 24-25, an exemplary actuator assembly withinternal clutching is shown generally at 310, provided with a clutchsystem shown generally at 312, where the actuator 310 is employable withany embodiment described herein. At least one actuator 310 with internalclutching is used or other actuator and/or in combination with anyadditional actuator(s) is/are used in the system.

The clutch system 312 comprises a housing portion indicated generally at312, an output shaft 316 which is received within and holds an outputdetent ring 318 and a moving detent ring 320.

During normal operation of the active side panel assembly 10, etc, theactuator assembly 310 provides power to drive and move the at least onepanel 22, etc between at least the stowed position and deployedposition. Also connected to the actuator assembly 310 is a rotatabledrive shaft, e.g., drive shaft 32, that is operably connected to the atleast one panel 22, etc and the output shaft 316 of the actuatorassembly 310. The drive shaft 32 functions to deploy the at least onepanel 22, etc in the event of predetermined conditions sensed by theactuator assembly 310 in order to move the at least one panel 22, etc toa fully extended deployed position for improved aerodynamics.

The output detent ring 318 is free to rotate on the output shaft 316about a portion of the output shaft 316 that is not splined. The movingdetent ring 320 is able to move axially to the output shaft 316 but islocked radially by a plurality of interlocking splines 322, 324 on bothcomponents. The output shaft 316 has interlocking splines 322 that arearranged parallel to the longitudinal axis and operably spaced about anouter surface located on a lower half of the output shaft 316. Themoving detent ring 320 has outer interlocking splines 324 formingcomplementary channels to slidably interlock with the interlockingsplines 322 for controlled axial movement of the moving detent ring 320.The interlocking splines 322 of the output shaft 316 terminate at anintegrally formed projecting ring 326 having an abutting surface 328,lying transverse to the axis, against which the output detent ring 318engages. The output detent ring 318 abuts against this surface 328 onthe output shaft 316 and does not move axially.

An output gear 330 is in mesh with the output detent ring 318 fortransmitting torque. The output gear 330 has spaced circumferentialsegments 332 that are generally square teeth like shaped held in placewithin opposing recesses 334 of the output detent ring 318 fortransmitting the torque.

The output and moving detent rings 318, 320 have first and secondintermeshing ramped teeth, generally shown at 336, 338, respectively,that are held together in mesh by the biasing force of a wave spring340. The wave spring 340 is received on the outer output shaft 316 andprovides a biasing force against the moving detent ring 320 in thedirection of the output detent ring 318.

The components of the clutch system 310 (e.g., output shaft 316, outputgear 330, output detent ring 318, moving detent ring 320, and wavespring 340) are held together by first and second locking rings 342, 344located toward respective ends the output shaft 316 of the clutchassembly 312.

A motor 346 selectively provides torque suitable for particularapplications. Suitable electronics 348, most preferably, a shut offprinted circuit board (PCB) with connector contacts 350 correlate withvehicle communication networks for commanding the motor 46 based uponpredetermined conditions, e.g., commanding energizing of the motorcorrelating with predetermined vehicle speed ranges. The PCB electronicssenses current spike for override, which allows the clutch to disengagethe drive system allowing it to rotate freely.

The motor 346 has a worm gear, shown generally at 352, which causes amain gear, shown generally at 354, to rotate. The main gear 354 has agear and a helix angle portion 358. The worm gear 352 has a shaft, e.g.,a threaded shaft, which engages the teeth of the gear 356, which causesthe gear 356 of the main gear 354 to rotate as the worm gear 352rotates. Rotation of the gear 356 causes the helix angle portion 358 ofthe main gear 354 to also rotate. The helix angle portion 358 rotatablyengages the output gear 330. The gear ratio range of the gear 356 tohelix angle portion 358 is operably suitable for transmitting torquefrom the motor/worm gear 346/352 to the output gear 330. The first andsecond intermeshing ramped teeth 336, 338 of the output and movingdetent rings 318, 320 when held together by the biasing force of thewave spring 340 lock and allow the output shaft 316 to rotate andtransmit the torque of the motor 346 through the main gear 354 andoutput gear 330 to the outside of the housing portion 314. The outputshaft 330 is operably coupled to the drive shaft 32 for selectivelyrotating, folding or otherwise moving at least one panel 22 etc betweenat least the stowed position and the deployed position. The wave spring340 allows for a more compact structure while meeting biasing andpredetermined load requirements.

The housing portion 314 comprises a first half 360 and a second half362. The first half 60 has a first clutch assembly cavity 364 and afirst motor cavity 366. The second half 362 has a second clutch assemblycavity 368, a main gear cavity 370, and a second motor cavity. Theclutch system 312 fits fully inside the first and second halves 360, 362of the housing (within the first and second clutch assembly cavities364, 368), as well as the motor 346 and electronics 348/350 (within thefirst motor cavity 366 and second motor cavity), and main gear 354(within the main gear cavity 370). The first and second halves 360, 362of the housing portion 314 are joined together, and connected withfasteners, and first and second seals added 372, 374 onto the outputshaft 316 to form a weathertight housing. The housing 314 may be formedin the rocker panel module 14, etc. without departing from the scope ofthe invention.

In operation, the first and second intermeshing ramped teeth 336, 338 ofthe output and moving detent rings 318, 320, that when held together bythe biasing force of the wave spring 340, lock together and allow theoutput shaft 316 to rotate. This allows torque transmission from themotor 346/worm gear 352 through the main gear 354 and output gear 330 tothe outside of the housing portion 314 via the output shaft 316 to thedrive shaft 32. During a predetermined level of high load, the first andsecond intermeshing ramped teeth 336, 338 create an axial force thatovercomes the load from the wave spring 340. This allows the movingdetent ring 320 to disengage and allow the output shaft 316 to rotatefreely, thereby preventing damage to the sealed actuator internalclutching assembly 310.

Thus, there is provided a sealed actuator with internal clutchingassembly 310 which can drive in both directions, but when stopped willhold its position without back driving when subjected to a predeterminedload, e.g., a load many times greater than its dynamic range. Theactuator 310 also protects itself from damage from predetermined loads,e.g., very high loads, by means of the clutch that will disengage thedrive system allowing it to rotate (e.g., allowing the output shaft 316to rotate freely). The sealed actuator with internal clutching assembly310 is in a waterproof housing and can rotate in both directions for asmany revolutions as needed. The clutch is fully self contained in thehousing. The actuator has an output passthrough drive structure, e.g.,output shaft 316 arrangement, allowing it to drive a shaft, e.g., driveshaft 32, or part from either side or both sides. The actuator 310 canbe mounted to a fixed part with the only external moving part is thedrive shaft 32. The clutch system 312 of the sealed actuator withinternal clutching assembly 310 also does not change shape or heightwhen it clutches, which is yet another significant advantage.

Referring to the Figures and embodiments generally, the panel 22, etc isadapted for attachment via at least one suitable fastener mechanism tothe rocker panel assembly and/or side step/bar and/or other framing orchassis member(s) depending on the application, e.g., via a pair ofhinges which can be any hinge arrangement suitable for predeterminedcycling and durability requirements, living hinge, or any other fasteneror the like. Alternatively, molded-in panel features which are used toattach to opposing vehicle features and/or in combination with at leastone fastener for each hinge or the like may be used depending on theapplication. In addition, typically, the deployable panel 22, etc ismovable from a deployed position to a stowed position. However,predetermined intermediate positions are contemplated without departingfrom the present invention. Additionally, tracks are contemplated formoving the panels, e.g., panels adapted with rollers translatable withinthe tracks between stages of deployment of the rollable panel from astowed position to the deployed position and back. Typically, the trackshave a ‘U’ shaped cross-section and are bolted in the base of the ‘U’ tothe rocker assembly, vehicle frame, chassis and/or other features.However, depending on the application tracks are welded, riveted,secured with adhesive and/or epoxy or otherwise connected depending onthe application. Optionally, each track includes a first end and asecond end with respective stop features in the second end. Class “A”surfaces on the housings and panels is contemplated. Panels withalternative profiles, angles, slants, etc are contemplated withoutdeparting from the scope of the invention.

The deployable panel 22, etc is made of a composite plastic in theseparticular embodiments. However, depending on the particularapplication, it is also within the scope of the invention to manufacturethe deployable panel 22, etc of different materials such as steel oraluminum, painted carbon fiber, extruded rubber, or other suitableimpact resistant material to withstand a predetermined load withoutdeparting from the scope of the invention. Additionally, the deployablepanel 22 etc may consist of a single piece, e.g., of molded compositeplastic, or multiple pieces assembled together.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. A deployable side panel assembly for a vehicle,comprising: at least one deployable panel having a predeterminedprofile, where said first extending panel selectively deploys andretracts between a deployed position and a stowed position, where thedeployment of the deployable panel improves aerodynamics; and at leastone actuator operably coupled to the at least one deployable panel,where the actuator has object detection and is in communication with thevehicle for automatically deploying of the deployable panel underpredetermined conditions and wherein the deployable panel is connectedto and deployable from under a rocker panel assembly and/or other undervehicle structural member.
 2. The deployable side panel assembly ofclaim 1, wherein the predetermined conditions are selected from vehiclespeed, wind direction, yaw, and combinations thereof.
 3. The deployableside panel assembly of claim 2, wherein the predetermined condition isat least vehicle speed in the range of at least 30 miles per hour. 4.The deployable side panel assembly of claim 1, wherein the actuatorautomatically retracts the deployable panel under predeterminedconditions selected from vehicle speed, wind direction, yaw, higherpredetermined loads, and combinations thereof.
 5. The deployable sidepanel assembly of claim 4, wherein the predetermined conditions are atleast vehicle speed in the range of less than 30 miles per hour and/orwhen the actuator senses higher predetermined loads.
 6. The deployableside panel assembly of claim 5, wherein the object detection compriseselectronics that sense current spike and provides circuit override. 7.The deployable side panel assembly of claim 6, wherein the actuator hasdeclutching of gearing so that the deployable panel can move freely outof the way to prevent damage.
 8. The deployable side panel assembly ofclaim 1, wherein the deployable panel is retracted upward to the stowedposition, allowing for improved deployable side panel assembly groundclearance.
 9. The deployable side panel assembly of claim 1, furthercomprising a threaded screw mechanism connected to the deployable panelto move the deployable panel between the deployed and vertical positionsas the mechanism is turned.
 10. The deployable side panel assembly ofclaim 1, wherein the deployable panel is formed of a flexible and/orstretchable material.
 11. The deployable side panel assembly of claim 1,further comprising a rocker panel assembly, wherein the deployable panelis connected to the rocker panel and the rocker panel comprises ahousing including an elongated opening sized for the deployable panel toselectively extend downward through to the deployed position whilepreventing a curved end of the deployable panel from moving laterallythrough the opening.
 12. The deployable side panel assembly of claim 1,wherein the predetermined profile of the deployable panel is eitherangled, straight, slanted, curved, or combinations thereof.
 13. Adeployable side panel assembly for a vehicle, comprising: at least onedeployable panel located substantially from front wheel well to rearwheel well of said vehicle, said at least one deployable panelselectively retracts upward to substantially horizontal underneath saidvehicle under predetermined conditions and selectively rotates downwardabout 90 degrees under predetermined conditions to a deployed positionbelow a rocker panel of said vehicle to improve crosswind aerodynamicsby preventing side air flow from entering under said vehicle; and atleast one actuator operably coupled to said at least one deployablepanel, wherein the actuator has object detection that senses currentspike for circuit override, and is in communication with the vehicle forautomatically deploying of the deployable panel under predeterminedconditions.
 14. The deployable side panel assembly of claim 1, furthercomprising a threaded flex screw mechanism operably connected to thedeployable panel to move the deployable panel a predetermined amount tothe deployed and stowed positions.